Apparatus for capturing axial force on an inner drive member

ABSTRACT

A spindle with a mechanism for transferring axial force from an inner drive assembly to an outer drive assembly. The spindle&#39;s inner drive shaft is connected to an inner member of a dual-rod pipe by a drive rod having a sliding sleeve. The sleeve is fixed rotationally with the drive shaft, but not axially. When axial force drives the drive rod toward the drive member of the spindle, the sleeve contacts a stop member which is paired to the outer drive assembly. The stop member may be a pair of dowel pins. Axial force is thereby transferred from the inner member to the outer member, allowing such forces to be absorbed by the outer member&#39;s larger drive components.

SUMMARY

The present invention is directed to an apparatus. The apparatus comprises an inner member, an outer member, an inner drive shaft, a hollow sleeve, and at least one pin. The inner member is disposed along a longitudinal axis. The outer member is at least partially surrounding the inner member and disposed about the longitudinal axis. The inner drive shaft is coupled to a motor. The hollow sleeve is joined to the inner member in sliding, torque-transmitting engagement with the inner drive shaft. The at least one pin is disposed through the outer member and transverse to the longitudinal axis. The at least one pin is configured to transmit axial force from the hollow sleeve to the outer member.

The present invention is also directed to a spindle. The spindle comprises an inner drive rod apparatus, a hollow outer member, and at least one stop member. The inner drive apparatus is disposed about a longitudinal axis and comprises a drive shaft, an inner drive rod, and a hollow sleeve. The inner drive rod is configured for connection to an inner member of a dual-member drive string. The hollow sleeve has a first end, a second end, and an internal surface. The hollow sleeve is slidingly supported and rotationally coupled to the drive shaft at its internal surface and joined to the drive rod at its first end. The hollow outer member is at least partially disposed about the inner drive rod apparatus. The outer member is independently rotatable relative to the inner drive rod apparatus. The at least one stop member is supported by the outer member and configured to engage with the second end of the hollow member.

In another aspect the invention is directed to an assembly for connecting a dual-member drill string to a gearbox. The dual-member drill string comprises independently rotatable inner and outer members. The assembly comprises an inner assembly, an outer assembly, and a stop member. The inner assembly is connected at a first end to the gearbox and a second end to the rotatable inner member of the dual-member drill string. The inner assembly comprises a drive shaft, a drive rod, and a hollow sleeve. The drive shaft is rotatable about a longitudinal axis and has a first outer diameter. The drive rod is configured for torque transmitting connection to the rotatable inner member. The hollow sleeve has a second outer diameter and is joined to the drive rod and partially surrounding the drive shaft in a torque-transmitting relationship. The hollow sleeve is configured to move axially relative to the drive shaft.

The outer assembly comprises a cavity in which the hollow sleeve and drive shaft are partially housed. The cavity defines a first inner diameter. The first inner diameter is greater than the first outer diameter and the second outer diameter. The stop member is disposed through the outer assembly and extends into the cavity. An effective inner diameter of the cavity at the stop member is greater than the first outer diameter and less than the second outer diameter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is dual pipe drill gearbox for use with a horizontal directional drilling machine.

FIG. 2 is a top view cross section of the gearbox of FIG. 1 .

FIG. 3 is a perspective view of the spindle assembly as shown in FIG. 1 . The gearbox shown in FIGS. 1-2 is attached to the right of the figure.

FIG. 4 is a cross section of the spindle assembly attached to the gearbox with the sliding sleeve and inner drive rod in a first position.

FIG. 5 is the cross section of the spindle assembly of FIG. 4 with the sliding sleeve and inner drive rod in a second, limiting position with the sleeve contacting a dowel rod.

FIG. 6 is a cross sectional end view of the spindle assembly showing a cross-section taken through line 6-6 of FIG. 5 .

FIG. 7 is a perspective view of the spindle assembly with a portion of the outer member of the spindle and retainer socket screws removed so that internal components of the spindle are visible. The sleeve is shown in the first position of FIG. 4 .

FIG. 8 is a diagrammatic representation of a horizontal directional drilling machine attached to a drill string.

DETAILED DESCRIPTION

In many horizontal directional drilling applications it is preferable to utilize a dual pipe system. Dual pipe systems are particularly useful for drilling through rock, as the rotation of the inner pipe and outer pipe may be used, independently of one another, to drive rotation of a drill bit and to change the orientation of a steering feature. An example of a dual pipe system is disclosed in U.S. Pat. No. 9,765,574, issued to Slaughter, Jr. et al (“Slaughter”), the contents of which are incorporated herein by reference.

With reference to FIG. 8 , a directional drilling machine 10 comprises a carriage 12. The carriage 12 provides axial and rotational force and is configured to connect sections of drill pipe 14 end to end to form a drill string 16. The drill string 16 comprises an outer and inner component. The inner pipe string is housed within the outer pipe string and may rotate independently of the outer pipe string.

The carriage 12 comprises a rotational drive system 20 and a linear drive system. The linear drive system moves the carriage along a rail to provide thrust and pull-back during a drilling operation. The rotational drive system 20, such as the system shown in FIG. 1 , is configured to provide torque for adding and removing pipe sections 14 from the drill string 16, and to provide the axial and rotational force used in drilling and backreaming procedures.

With reference to FIGS. 1 and 2 , the rotational drive system 20, or gearbox, comprises an inner pipe motor 22 and an outer pipe motor 24. The outer pipe motor 24 provides torque to the outer pipe string and the inner pipe motor 22 provides torque to the inner pipe string. Torque is transferred from the gearbox 20 to the drill string 16 through a spindle 30. The spindle 30 has inner and outer components, as shown in FIGS. 2-7 , which are preferably substantially centered about a longitudinal axis 31. The axis 31 is also an axis of rotation for the inner and outer components of the spindle 30.

The gearbox 20 comprises an outer output gear 26 and an inner output gear 28. The outer output gear 26, driven by the outer motor 24, transmits torque to an outer drive shaft 32. Likewise, the inner output gear 28, driven by the inner motor 22, transmits torque to the inner drive shaft 34. The inner drive shaft 34 and outer drive shaft 32 rotate independently of each other. The outer drive shaft 32 is supported by a plurality of outer drive shaft bearings 36. Likewise, the inner drive shaft 34 is held in place by a plurality of inner drive shaft bearings 37. The inner 34 and outer 32 drive shafts transmit torque to the drill string 16 through the spindle 30.

With reference to FIGS. 3-7 , components of the spindle 30 are shown. The spindle 30 comprises an outer member 40 which is rotationally joined to the outer drive shaft 32 by a plurality of retainer socket screws 42 disposed in a flange 44 of the outer member 40. The inner drive shaft 34, or a stub joined thereto, is disposed within a cavity 46 formed in the outer member 40. The outer member 40 has an end 48 which is configured for connection to an outer member of the drill string 16. The outer member 40 may also have an opening for a connection to a wireline.

An inner drive rod apparatus 50 is disposed within the outer member 40. The inner drive rod apparatus 50 comprises a collar 52, a drive rod 54, and a hollow sleeve 56. The collar 52 is configured for connection to an inner member of a dual member drill string 16. As shown, the collar 52 has a torque-transmitting inner profile for imparting rotation to the inner member of the drill string 16. The hollow sleeve 56 may be formed integrally with the drive rod 54 or may be joined by a circumferential weld 58.

The hollow sleeve 56, as shown, has an internal profile 60 which conforms to an outer profile 62 of the drive shaft 34. The profiles 60, 62, are configured for torque-transmitting connection during rotation of the drive shaft 34. However, the profiles 60, 62 are also configured to allow sliding relative movement between the drive shaft 34 and hollow sleeve 56 within a range of motion.

As best shown in FIG. 6 , the profiles 60, 62 comprise complementary interlocking splines. However, other geometry may be utilized, including, but not limited to polygonal profiles, protrusions or depressions with torque-transmitting elements, and the like. Further, while the profile 60 of the sleeve 56 is shown on its inner surface and the profile 62 of the drive shaft 34 on its outer surface, other orientations which allow relative axial movement but allow torque transmission may be utilized.

A spring 70 is disposed between the drive shaft 34 and the drive rod 54. The spring 70 biases the drive rod 54 to a forward position as shown in FIG. 4 , away from the gearbox 20. As drilling operations continue, the drive rod 54 may be forced in a direction toward the gearbox 20. As shown in FIG. 5 , as the spring 70 compresses, the inner drive rod 54 and sleeve 56 are forced axially towards the gearbox 20.

With reference again to FIG. 8 , during makeup of a pipe section 14 to the drill string 16, inner and outer pipe connections are made up simultaneously. There is, however, the potential for misalignment between the ends of the inner pipe sections while adjacent outer pipe sections are threadedly connected. This scenario can cause the inner pipe section which is attached to the inner drive rod 54 to be unintentionally forced axially toward the gearbox 20. If the inner drive rod 54 is forced into the gearbox 20, the axial force may be transferred to one or more of the plurality of inner drive shaft 34 or gearbox bearings 37. The force exerted on the bearings 37 may cause considerable damage to the gearbox 20.

The present invention solves this problem by transferring the axial load of the inner drive rod 54 to the outer member 40, and therefore to the outer drive shaft 32. The outer gearbox bearings 36 are much larger than the inner gearbox bearings 37 and may withstand the axial loads which may be exerted by the inner drive rod.

The spindle 30 comprises a stop member 80 defining a limit of the axial movement of the sleeve 56 in a direction toward the gearbox 20. The stop member 80 is preferably transverse to the longitudinal axis 31 of the spindle 30. The sleeve 56 terminates in a shoulder 57. This shoulder 57, at its limit of axial movement, contacts the stop member 80.

The stop member 80 is disposed through the outer member 40. As a result, axial force transmitted through the drill rod 54 and sleeve 56 will transfer to the outer member 40 (and thus components of the outer member's rotational drive) rather than the inner drive shaft 34. The stop member 80 is positioned, as best shown in FIG. 6 , such that it reduces the effective inner diameter of the cavity 46 such that it is less than an outer diameter of the sleeve 56, but greater than the outer diameter of the drive shaft 34.

As shown, the stop member 80 comprises two spaced-apart dowel pins 82. Each dowel pin 82 is trapped within a pair of transfer bolts 84. Through-holes 86 are provided in the flange 44 of the outer member 40. The through-holes 86 are spaced such that the pins 82 sit parallel to each other, with one pin situated on each side of the inner drive shaft 34. The distance between the parallel pins 82 is greater than the diameter of the inner drive shaft 34, but less than the diameter of the sleeve 56. This allows the inner drive shaft 34 to rotate independently of the outer member 40 without interference from the dowel pins 82, but does allow engagement between the shoulder of the sleeve 56 and the dowel pins 82. The transfer bolts 84 are preferably sealing bolts to prevent leakage of drilling fluid.

Upon engagement of the sleeve 56 with the dowel pins 82, the axial force that would have been transmitted to the inner drive shaft 34 is now transmitted to the outer member 40, and subsequently to the outer drive shaft 32. As stated above, the outer drive shaft 32 is designed to regularly withstand high axial loads.

To assemble the spindle 30, the outer member 40 is placed over the assembled inner drive components, including the drive rod 54, sleeve 56 and inner drive shaft 34. The outer member 40 is then attached to the gearbox 20 with the retainer socket screws 42. Finally, the dowel pins 82 are inserted into the through holes 86 in the flange 44 and held in place by the installation of the transfer bolts 84.

As shown, the spindle 30 is configured to run drill pipe 14 in the “pin-up” configuration. Each outer pipe section comprises a pin end and a box end. The outer member 40 comprises a box end 90 that may threadedly engage with the pin end of an outer pipe section. The inner drive rod 54 is attached to the collar 52, which may likewise provide a hexagonal box end 92 for connection to an inner pipe section. Other geometric shapes, such as is provided for in Slaughter, may also be used.

Each inner pipe section comprises a pin end with a complementary outwardly facing geometric shape that is slideably receivable within the collar 52. Each inner pipe section comprises a box end and a pin end. This configuration provides transmission of torque between the inner drive rod and an adjacent inner pipe section and between adjacent inner pipe sections. The inner drive shaft 34 and drive rod 52 may comprise an internally-disposed fluid passage 95 centered upon the longitudinal axis 31 of the spindle 30. The passage 95 may be used for the transmission of drilling fluid downhole.

The various features and alternative details of construction of the apparatuses described herein for the practice of the present technology will readily occur to the skilled artisan in view of the foregoing discussion, and it is to be understood that even though numerous characteristics and advantages of various embodiments of the present technology have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the technology, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present technology to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

What is claimed is:
 1. An apparatus, comprising: an inner member disposed along a longitudinal axis; an outer member at least partially surrounding the inner member and disposed about the longitudinal axis; an inner drive shaft coupled to a motor; a hollow sleeve joined to the inner member and in sliding, torque-transmitting engagement with the inner drive shaft; a compression spring disposed between the inner member and the inner drive shaft; and at least one pin disposed through the outer member and transverse to the longitudinal axis, configured to transmit axial force from the hollow sleeve to the outer member.
 2. The apparatus of claim 1 wherein the at least one pin comprises two pins.
 3. The apparatus of claim 1 wherein: the hollow sleeve has an inner surface defined by splines; and the inner drive shaft has an outer surface defined by splines, complementary to the splines of the hollow sleeve.
 4. A spindle, comprising: an inner drive rod apparatus disposed about a longitudinal axis, comprising: a drive shaft; an inner drive rod, configured for connection to an inner member of a dual-member drill string; and a hollow sleeve, having a first end, a second end, and an internal surface, wherein the hollow sleeve is slidingly supported and rotationally coupled to the drive shaft at the internal surface of the sleeve and joined to the drive rod at the first end of the sleeve; a hollow outer member at least partially disposed about the inner drive rod apparatus, the outer member being independently rotatable relative to the inner drive rod apparatus; and at least two pins supported by the outer member disposed on opposed sides of the drive shaft at a distance greater than an outer diameter of the drive shaft but less than an outer diameter of the hollow sleeve, the two pins configured to engage with the second end of the hollow sleeve.
 5. The spindle of claim 4 in which the hollow sleeve is joined to the inner drive rod by a weld.
 6. The spindle of claim 4 further comprising a collar, in which the collar is attached to the inner drive rod and configured for connection to a pin end of an inner member of the drill string.
 7. The spindle of claim 4 in which: the drive shaft of the inner drive rod apparatus comprises an outer surface defined by a plurality of torque-transmitting features; and the inner surface of the hollow sleeve is defined by a plurality of features complementary to the torque-transmitting features of the drive shaft.
 8. The spindle of claim 7 in which the torque-transmitting features are splines.
 9. A spindle, comprising: an inner drive rod apparatus disposed about a longitudinal axis, comprising: a drive shaft; an inner drive rod, configured for connection to an inner member of a dual-member drill string; and a hollow sleeve, having a first end, a second end, and an internal surface, wherein the hollow sleeve is slidingly supported and rotationally coupled to the drive shaft at the internal surface of the sleeve and joined to the drive rod at the first end of the sleeve; a hollow outer member at least partially disposed about the inner drive rod apparatus, the outer member being independently rotatable relative to the inner drive rod apparatus; and at least one stop member supported by the outer member configured to engage with the second end of the hollow sleeve; and further comprising a compression spring disposed between the inner drive rod and the drive shaft.
 10. The spindle of claim 9 in which the at least one stop member is transverse to the longitudinal axis of the inner drive rod apparatus.
 11. A drilling machine, comprising: a gearbox comprising: a first motor; a first output gear rotationally driven by the first motor; a second motor; and a second output gear rotationally driven by the second motor; and the spindle of claim 9; wherein the hollow outer member is rotationally driven by the first output gear; and wherein the drive shaft of the inner drive rod apparatus is rotationally driven by the second output gear.
 12. The drilling machine of claim 11 wherein: the hollow sleeve defines a limit position, wherein the hollow sleeve contacts the stop member in the limit position; and wherein the stop member is configured to transfer axial force from the hollow sleeve to the outer member when the hollow sleeve is in the limit position.
 13. An assembly for connecting a dual-member drill string to a gearbox, the dual-member drill string comprising independently rotatable inner and outer members, the assembly comprising: an inner assembly, connected at a first end to the gearbox and a second end to the rotatable inner member of the dual-member drill string, the inner assembly comprising: a drive shaft, rotatable about a longitudinal axis and having a first outer diameter; a drive rod configured for torque-transmitting connection to the rotatable inner member; and a hollow sleeve having a second outer diameter, the sleeve being joined to the drive rod and partially surrounding the drive shaft in a torque-transmitting relationship; wherein the hollow sleeve is configured to move axially relative to the drive shaft; an outer assembly comprising a cavity in which the drive shaft and hollow sleeve are partially housed, the cavity defining a first inner diameter, in which the first inner diameter is greater than the first outer diameter and the second outer diameter; and a stop member disposed through the outer assembly and extending into the cavity, wherein an effective inner diameter of the cavity at the stop member is greater than the first outer diameter and less than the second outer diameter.
 14. The assembly of claim 13 in which: the outer assembly is joined to the outer member; and the drive rod is connected to the inner member.
 15. The assembly of claim 14 in which the drive rod comprises a collar having a torque-transmitting profile, and wherein the inner member is partially disposed within the collar.
 16. The assembly of claim 13 in which the stop member comprises two pins disposed within the cavity and transverse to the longitudinal axis. 